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Heating, Ventilation and Air Conditioning: Removal & Installation GMC Envoy II

Automatic HVAC System 1 illustration ~9027 words

Removal Procedure

  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Remove the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical.
  3. Remove the idler pulley. Refer to «Drive Belt Idler Pulley Replacement»(ref-200396-S37180570702005102000000) in Engine Mechanical-4.2L.
  4. Disconnect the compressor electrical connectors.
  5. Remove the compressor hose assembly bolt from the compressor.
  6. Remove the compressor hose assembly block from the compressor.
  7. Remove the compressor mounting bolts from the compressor (1).
  8. Remove the compressor.
  9. Drain and measure the compressor oil. Refer to «Compressor Oil Balancing»(ref-200405-S31444867252005102000000) .

Installation Procedure

  1. Add the proper amount of oil to the replacement compressor. Refer to «Compressor Oil Balancing»(ref-200405-S31444867252005102000000) .
  2. Install the compressor.
  3. Install the compressor mounting bolts to the compressor (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  4. Install the compressor hose assembly block to the compressor.
  5. Install the compressor hose assembly bolt to the compressor (1). Tighten: Tighten the bolt to 33 N.m (24 lb ft).
  6. Connect the compressor electrical connectors.
  7. Install the idler pulley. Refer to «Drive Belt Idler Pulley Replacement»(ref-200396-S37180570702005102000000) in Engine Mechanical.
  8. Install the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical.
  9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  10. Leak test the fittings of the components using the J 39400-A .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Remove the washer solvent container. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wipers/Washer Systems.
  3. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.
  4. Remove the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
  5. Release the tension on the air conditioning drive belt.
  6. Reposition the air conditioning drive belt from the compressor pulley.
  7. Remove the compressor hose assembly nut from the compressor.
  8. Remove the compressor hose assembly from the compressor.
  9. Remove the upper A/C compressor mounting bracket bolts.
  10. Remove the lower coolant hose. Refer to «Radiator Hose Replacement - Inlet (LM4)»(ref-200409-S38972980032005102000000) or «Radiator Hose Replacement - Inlet (LL8)»(ref-200409-S01016099022005102000000) in Engine Cooling.
  11. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
  12. Disconnect the electrical connection from the compressor.
  13. Turn the right tire to gain access to the remaining compressor mounting bolts.
  14. Remove the lower A/C compressor mounting bracket bolts (3).
  15. Lower the vehicle.
  16. Reposition the compressor and mounting bracket to access the remaining compressor to bracket bolts.
  17. Remove the upper A/C compressor mounting bolts (4).
  18. Remove the A/C compressor.
  19. Remove the A/C compressor bracket.
  20. If replacing the A/C compressor, refer to «Compressor Oil Balancing»(ref-200405-S31444867252005102000000) .
  1. Add the proper amount of polyalkylene glycol (PAG) oil to the compressor crankcase. Refer to «Compressor Oil Balancing»(ref-200405-S31444867252005102000000) .
  2. Position the A/C compressor mounting bracket partially into the vehicle.
  3. Position the A/C compressor partially into the vehicle.
  4. Install the upper compressor mounting bolts into the compressor mounting bracket. Tighten: Tighten the upper rear bolts to 50 N.m (37 lb ft).
  5. Install the upper compressor mounting bolts (4) into the compressor and bracket assembly.
  6. Position the compressor and bracket assembly into the correct location on the engine.
  7. Tighten the upper compressor mounting bolts (4). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  8. Raise the vehicle
  9. Start the lower compressor mounting bolts (3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  10. Connect the electrical connector to the A/C compressor.
  11. Raise the vehicle.
  12. Install the lower coolant hose. Refer to «Radiator Hose Replacement - Inlet (LM4)»(ref-200409-S38972980032005102000000) or «Radiator Hose Replacement - Inlet (LL8)»(ref-200409-S01016099022005102000000) in Engine Cooling.
  13. Install the compressor hose assembly to the compressor.
  14. Install the compressor hose assembly nut to the compressor. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  15. Install the accessory drive belt to the tensioner.
  16. Install the cooling fan and shroud. Refer to «Cooling Fan and Shroud Replacement»(ref-200409-S21303519892005102000000) in Engine Cooling.
  17. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-200373-S04937318252005102000000) in Engine Controls - 5.3L.
  18. Install the washer solvent container. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wipers/Washer Systems.
  19. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  20. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  21. Leak test the fittings of the component using the J 39400-A .
  1. Remove the seal washer from the A/C refrigerant component.
  2. Inspect the seal washer for signs of damage to help determine the root cause of the failure.
  3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  4. Discard the sealing washer.
  1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
  4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting.
  5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.
  1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). For banjo style fittings remove the bolt retaining the banjo type fitting.
  2. Remove the O-ring seal from the A/C refrigerant component.
  3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.
  4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
  5. Cap or tape the A/C refrigerant components.
  6. Discard the O-ring seal.
  1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
  2. Remove the cap or tape from the A/C refrigerant components.
  3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
  4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
  5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
  6. The O-ring seal must be fully seated.
  7. Assemble the A/C components. Refer to the appropriate repair procedure. For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Remove the compressor hose assembly nut (3).
  3. Remove the compressor hose assembly from the compressor (4).
  4. Remove the sealing washers.
  5. Remove the compressor suction hose nut from the accumulator.
  6. Remove the compressor suction hose from the accumulator.
  7. Remove the O-ring seal.
  8. Remove the bolt from the lift bracket.
  9. Remove the nut from the engine stud.
  10. Remove the compressor discharge hose (2) from the condenser (4).
  11. Remove the nut from compressor hose connection in driver wheel opening.
  12. Remove the O-ring seals.
  13. Cap or plug all of the open connections.
  1. Install new O-ring seals. Refer to «O-Ring Replacement»(ref-200405-S33892836282005102000000) .
  2. Install the compressor discharge hose (2) to the condenser (4).
  3. Install the compressor discharge hose nut. Tighten: Tighten the hose nut to 28 N.m (21 lb ft).
  4. Install the compressor hose to the connector through the driver wheel opening.
  5. Install the nut. Tighten: Tighten the nut to 48 N.m (35 lb ft).
  6. Install the compressor suction hose to the stud on the engine.
  7. Install the nut. Tighten: Tighten the nut to 48 N.m (35 lb ft).
  8. Install the compressor suction hose to the engine lift bracket.
  9. Install the bolt. Tighten: Tighten the bolt to 48 N.m (35 lb ft).
  10. Connect the compressor suction hose (1) to the accumulator.
  11. Install the compressor suction hose nut to the accumulator. Tighten: Tighten the nut to 48 N.m (35 lb ft).
  12. Install the sealing washers. Refer to «Sealing Washer Replacement»(ref-200405-S18496484372005102000000) .
  13. Connect the compressor hose assembly hose to the compressor (4).
  14. Install the compressor hose assembly washers.
  15. Install the retaining nut (3). Tighten: Tighten the nut to 33 N.m (24 lb ft).
  16. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  17. Leak test the fittings of the components using the J 39400-A .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Remove the washer bottle. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wipers/Washer Systems.
  3. Remove the retaining nut (1) from the compressor hose (4) at the accumulator (2).
  4. Remove the retaining nut from the compressor hose at the auxiliary HVAC piping connection (3).
  5. Remove the compressor hose from the accumulator (2).
  6. Remove the compressor hose from the auxiliary HVAC piping.
  7. Disconnect the pressure sensor electrical connector.
  8. Remove the compressor hose mounting nut (2) from the A/C compressor.
  9. Remove the heater hose bracket nut at the engine.
  10. Remove the bracket from the stud.
  11. Turn the compressor hose assembly to clear the heat shield.
  12. Lift and remove the compressor hose assembly from the compressor.
  13. Remove the compressor hose assembly from the condenser.
  14. Remove the compressor hose assembly.
  15. Remove the compressor hose from the A/C compressor.
  16. Remove the compressor hose from the condenser.
  17. Disconnect the electrical connector from the A/C low pressure switch.
  18. Remove the nut from the compressor hose at the accumulator.
  19. Remove the compressor hose from the accumulator.
  20. Remove the compressor hose from the vehicle.
  21. Discard all of the used sealing washers. Cap the system openings.
  1. Install the compressor hose assembly.
  2. Install the compressor hose to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-200405-S18496484372005102000000) .
  3. Install the compressor hose nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  4. Connect the electrical connector to the A/C low pressure switch.
  5. Install the compressor hose to the accumulator using new sealing washers. Refer to «Sealing Washer Replacement»(ref-200405-S18496484372005102000000) .
  6. Install the nut (1) to the accumulator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  7. Install the compressor hose (1) to the A/C compressor using new sealing washers. Refer to «Sealing Washer Replacement»(ref-200405-S18496484372005102000000) .
  8. Install the compressor hose nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  9. Install the washer bottle. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wipers/Washer Systems.
  10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  11. Leak test the fittings of the component using J 39400-A .

Evaporator Tube Replacement

Tools Required

  1. J 26549-E Orifice Tube Remover. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. J 39400-A Halogen Leak Detector
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Loosen the evaporator tube (5) from the evaporator.
  3. Loosen the auxiliary evaporator tube (7) from the auxiliary piping.
  4. Remove the evaporator tube nut from the condenser.
  5. Remove the nuts (1,2) retaining the evaporator tube to the fender.
  6. Remove the washer solvent container. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wipers/Washer Systems.
  7. Remove the coolant recovery tank. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  8. Remove the evaporator tube using J 26549-E . See «Special Tools»(ref-200405-S14942364402005102000000) .
  9. Remove the O-ring seal and discard.
  1. Install the new O-ring seal. Refer to «O-Ring Replacement»(ref-200405-S33892836282005102000000) .
  2. Install the evaporator tube.
  3. Connect the evaporator tube to the evaporator (5). Tighten: Tighten the nut to 28 N.m (21 lb ft).
  4. Connect the auxiliary evaporator tube to the auxiliary piping. Tighten: Tighten the nut to 28 N.m (21 lb ft).
  5. Connect the evaporator tube to the condenser. Tighten: Tighten the nut to 28 N.m (21 lb ft).
  6. Install the coolant recovery tank. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  7. Install the washer solvent container. Refer to «Washer Solvent Container Replacement (Envoy, TrailBlazer)»(ref-200389-S19089800582005102000000) or «Washer Solvent Container Replacement (Rainier)»(ref-200389-S14905152262005102000000) in Wipers/Washer Systems.
  8. Install the nuts (1,2) retaining the evaporator tube to the fender. Tighten: Tighten the nuts to 28 N.m (21 lb ft).
  9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  10. Leak test the fittings of the components using the J 39400-A .

Expansion (Orifice) Tube Replacement (Front Only System)

Tools Required

  1. J 26549-E Orifice Tube Remover. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. J 39400-A Halogen Leak Detector
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Remove the accumulator. Refer to «Accumulator Replacement»(ref-200405-S40893416132005102000000) .
  3. Remove the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  4. Remove the evaporator tube nut (3) at the evaporator (1).
  5. Remove the evaporator tube (4) from the evaporator (1).
  6. Remove the O-ring seal and discard.
  7. Remove the nut from the evaporator tube block fitting.
  8. Separate the evaporator tubes (4,6) at the block fitting.
  9. Use the J 26549-E in order to remove the expansion tube. See «Special Tools»(ref-200405-S14942364402005102000000) .
  10. Remove the expansion tube from the evaporator tube (6).
  1. Use the J 26549-E in order to install the expansion tube. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. Install the new O-ring seal. Refer to «O-Ring Replacement»(ref-200405-S33892836282005102000000) .
  3. Assemble the evaporator tubes (4,6).
  4. Install the evaporator tube nut. Tighten: Tighten the nut to 28 N.m (21 lb ft).
  5. Connect the evaporator tube (4) to the evaporator (1).
  6. Install the nut (3). Tighten: Tighten the nut to 28 N.m (21 lb ft).
  7. Install the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  8. Install the accumulator. Refer to «Accumulator Replacement»(ref-200405-S40893416132005102000000) .
  9. Recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  10. Leak test the fittings of the components using the J 39400-A .

Expansion (Orifice) Tube Replacement (Auxiliary System)

Tools Required

  1. J 26549-E Orifice Tube Remover. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. J 39400-A Halogen Leak Detector
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Remove the accumulator. Refer to «Accumulator Replacement»(ref-200405-S40893416132005102000000) .
  3. Remove the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  4. Loosen the evaporator tube nut (5) from the evaporator.
  5. Remove the evaporator tube from the evaporator.
  6. Remove the nut (2) from the evaporator tube block (3).
  7. Separate the evaporator tube at the block fitting (3).
  8. Use the J 26549-E in order to remove the expansion tube (4). See «Special Tools»(ref-200405-S14942364402005102000000) .
  9. Remove the O-ring seal and discard.
  10. Remove the expansion tube (4) from the evaporator tube (1).
  1. Install the expansion tube (4) to the evaporator tube (1).
  2. Use the J 26549-E in order to install the expansion tube (4). See «Special Tools»(ref-200405-S14942364402005102000000) .
  3. Install the new O-ring seal. Refer to «O-Ring Replacement»(ref-200405-S33892836282005102000000) .
  4. Assemble the evaporator tube at the block fitting (3).
  5. Install the nut (2) to the evaporator tube block (3). NOTE: Refer to «Fastener Notice»(ref-200361-S03298564292005102000000) in Cautions and Notices. Install the evaporator tube nut. Tighten: Tighten the nut to 28 N.m (21 lb ft).
  6. Install the evaporator tube to the evaporator.
  7. Install the evaporator tube nut (5) to the evaporator. Tighten: Tighten the nut to 28 N.m (21 lb ft).
  8. Install the coolant reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  9. Install the accumulator. Refer to «Accumulator Replacement»(ref-200405-S40893416132005102000000) .
  10. Recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  11. Leak test the fittings of the components using the J 39400-A .
  1. Remove the protective cover from the underhood fuse block.
  2. Remove the compressor relay (1) from the underhood fuse block (2).
  1. Install the compressor relay (1) to the underhood fuse block (2).
  2. Install the protective hood to the underhood fuse block.
  1. Disconnect the A/C low pressure switch electrical connector.
  2. Remove the A/C low pressure switch (2) from the accumulator (1).
  3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator.
  1. Install the new O-ring seal. Refer to «O-Ring Replacement»(ref-200405-S33892836282005102000000) .
  2. Install the A/C low pressure switch (2) to the accumulator (1). Tighten: Tighten the A/C low pressure switch to 4.8 N.m (42 lb in).
  3. Connect the A/C low pressure switch electrical connector.
  4. Leak test the fittings of the components using the J 39400-A .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
  2. Disconnect the electrical connector from the A/C refrigerant pressure sensor. The connector is accessible through the lower control arm.
  3. Remove the A/C refrigerant pressure sensor from the compressor hose block.
  4. Remove and discard the O-ring seal from the A/C refrigerant pressure sensor.
  1. Install the new O-ring seal. Refer to «O-Ring Replacement»(ref-200405-S33892836282005102000000) .
  2. Install the A/C refrigerant pressure sensor to the compressor hose block. Tighten: Tighten the A/C refrigerant pressure sensor to 4.8 N.m (42 lb in).
  3. Connect the electrical connector to the A/C refrigerant pressure sensor.
  4. Leak test the fittings of the component using J 39400-A .
  5. Lower the vehicle.
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Remove the compressor discharge hose nut (1) from the condenser (4).
  3. Remove the compressor discharge hose (2) from the condenser (4).
  4. Remove the evaporator tube nut (5) from the condenser (3).
  5. Remove the evaporator tube (4) from the condenser (3).
  6. Remove the hood latch. Refer to «Hood Replacement»(ref-200376-S28686116562005102000000) in Body Front End.
  7. Remove the retaining screws from the condenser.
  8. Remove the condenser from the radiator.
  1. Install the condenser to the radiator.
  2. Install the retaining screws to the condenser. Tighten: Tighten the screws to 5 N.m (44 lb in).
  3. Install the hood latch. Refer to «Hood Replacement»(ref-200376-S28686116562005102000000) in Body Front End.
  4. Connect the evaporator tube (4) to the condenser (3).
  5. Install the retaining nut to the evaporator tube (4) at the condenser (3). Tighten: Tighten the nut to 28 N.m (21 lb ft).
  6. Connect the compressor discharge hose (2) to the condenser (4).
  7. Install the retaining nut (1) to the compressor discharge hose (2) at the condenser (4). Tighten: Tighten the nut to 28 N.m (21 lb ft).
  8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  9. Leak test the fittings of the components using J 39400-A .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Disconnect the electrical connector from the A/C pressure switch.
  3. Remove the A/C low pressure switch.
  4. Remove the nut (3) retaining the accumulator (4) to evaporator (1).
  5. Remove the compressor suction hose assembly from the accumulator.
  6. Remove and discard the O-ring seals.
  7. Remove the accumulator clamp nut.
  8. Remove the accumulator from the vehicle.
  1. Install the accumulator to the vehicle.
  2. Install the accumulator into the accumulator clamp.
  3. Install the accumulator clamp nut. Tighten: Tighten the nut to 10 N.m (88 lb in).
  4. Install the A/C low pressure switch. Tighten: Tighten the A/C low pressure switch to 5 N.m (44 lb in).
  5. Install new O-ring seals. Refer to «O-Ring Replacement»(ref-200405-S33892836282005102000000) .
  6. Install the accumulator to the evaporator.
  7. Install the accumulator retaining nut. Tighten: Tighten the nut to 28 N.m (21 lb ft).
  8. Connect the compressor suction hose to the accumulator (4).
  9. Install the suction hose nut. Tighten: Tighten the nut to 48 N.m (35 lb ft).
  10. Connect the electrical connector to the A/C low pressure switch.
  11. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  12. Leak test the fitting of the component using the J 39400-A .

HVAC Module Assembly Replacement

Tools Required

  1. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. J 39400-A Halogen Leak Detector
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  3. Remove the instrument panel (I/P) carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-200362-S10043836912005102000000) in Instrument Panel, Gages and Console.
  4. Reposition the heater hose clamps using J 43181 . See «Special Tools»(ref-200405-S14942364402005102000000) .
  5. Disconnect the heater hoses from the heater core.
  6. Remove the retaining nut (3) from the accumulator (6) at the evaporator (1).
  7. Disconnect the accumulator (6) from the evaporator (1).
  8. Disconnect the evaporator tube (4) from the evaporator (1).
  9. Disconnect all of the electrical connectors to the HVAC module assembly.
  10. Remove the HVAC module assembly.
  1. If replacing the HVAC module assembly (8), transfer the components from the old HVAC module assembly as necessary.
  2. Install the HVAC module assembly (8).
  3. Connect all of the electrical connectors to the HVAC module assembly.
  4. Connect the heater hoses to the heater core.
  5. Connect the evaporator tube (4) to the evaporator (1).
  6. Install the accumulator (6) to the evaporator (1).
  7. Tighten the accumulator retaining nut. Tighten: Tighten the nut to 4.5 N.m (40 lb in).
  8. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-200362-S10043836912005102000000) in Instrument Panel, Gages and Console.
  9. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  10. Leak test the fittings of the components using the J 39400-A .
  11. Refill the engine coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  2. Remove the screws to separate the HVAC module assembly halves.
  3. Separate the HVAC module assembly (1).
  4. Remove the evaporator core (2) from the HVAC module assembly (1).
  5. Remove the seal between the HVAC module assembly halves.
  1. Install the seal between the HVAC module assembly halves.
  2. Install the evaporator core (2) to the HVAC module assembly (1).
  3. Assemble the HVAC module assembly.
  4. Install the screws to join the HVAC module assembly halves. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .

Heater Hose Replacement - Inlet (Front System Only)

Tools Required

  1. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. J 38185 Hose Clamp Pliers
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  2. Using the J 43181 , disconnect the inlet heater hose (2) from the heater core inlet tube. See «Special Tools»(ref-200405-S14942364402005102000000) . Install the J 43181 to the quick connect on the outlet heater core hose (2). See «Special Tools»(ref-200405-S14942364402005102000000) . Close the tool around the inlet heater core hose. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose (2). Pull the heater hose forward in order to disengage the hose from the heater core.
  3. Position the inlet heater hose clamp (1) at the engine block using J 38185 .
  4. Remove the heater inlet hose (2) from the inlet hose fitting at the engine block.
  5. Remove the heater inlet hose.
  1. Apply coolant to the end of the heater inlet hose.
  2. Install the heater inlet hose (2) to the inlet hose fitting at the engine block.
  3. Position the inlet heater hose clamp (1) at the engine block using J 38185 .
  4. Install the quick connect end of the outlet heater core hose (2) to the heater core.
  5. Fill the engine cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.

Heater Hose Replacement - Inlet (Auxiliary System)

Tools Required

  1. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. J 38185 Hose Clamp Pliers
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  2. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  3. Using the J 43181 disconnect the inlet heater hose (2) from the heater core inlet tube. See «Special Tools»(ref-200405-S14942364402005102000000) . Install the J 43181 to the quick connect on the outlet heater core hose (2). See «Special Tools»(ref-200405-S14942364402005102000000) . Close the tool around the inlet heater core hose. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
  4. Reposition the hose clamp at the engine outlet using J 38185 .
  5. Remove the heater inlet hose (4) from the engine block.
  6. Remove the nut retaining the coolant bypass valve to the cowl.
  7. Remove the heater inlet hose.
  1. Apply coolant to the end of the heater inlet hoses.
  2. Install the heater inlet hose to the inlet hose fitting at the engine block.
  3. Install the nut retaining the coolant bypass valve to the cowl. Tighten: Tighten the nut to 10 N.m(89 lb in).
  4. Install the inlet heater hose to the engine block.
  5. Reposition the inlet heater hose clamp at the engine block using J 38185 .
  6. Install the quick connect end of the inlet heater core hose to the heater core.
  7. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  8. Fill the engine cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.

Heater Hose Replacement - Outlet (Front Only System)

Tools Required

  1. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. J 38185 Hose Clamp Pliers
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  2. Remove the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60/4L65-E.
  3. Remove the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical.
  4. Using the J 43181 disconnect the outlet hose from the heater core outlet tube (1). See «Special Tools»(ref-200405-S14942364402005102000000) . Install the J 43181 to the outlet heater core hose. See «Special Tools»(ref-200405-S14942364402005102000000) . Close the tool around the outlet heater core hose. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
  5. Remove the heater outlet hose (3) from the heater core (1).
  6. Position the outlet heater hose clamp (6) at the water pump using J 38185 .
  7. Remove the heater outlet hose (7) from the outlet hose fitting.
  8. Remove the heater outlet hose.
  1. Install the outlet heater hose.
  2. Install the heater outlet hose (7) to the outlet hose fitting.
  3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185 .
  4. Install the heater outlet hose (3) to the heater core (1).
  5. Firmly push the quick connect onto the heater core hose until you hear an audible click.
  6. Install the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60/4L65-E.
  7. Install the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-200375-S31589748562005102000000) or «Generator Replacement (5.3L Engine)»(ref-200375-S15757633622005102000000) in Engine Electrical.
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.

Heater Hose Replacement - Outlet (Auxiliary System)

Tools Required

  1. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. J 38185 Hose Clamp Pliers
  1. Remove the coolant bypass valve. Refer to «Coolant Bypass Valve Replacement»(ref-200405-S02566524482005102000000) .
  2. Remove the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60/4L65-E.
  3. Remove the heater outlet hose (3) from the heater core (1).
  4. Position the outlet heater hose clamp (6) at the water pump using J 38185 .
  5. Remove the heater outlet hose (7) from the outlet hose fitting.
  6. Remove the heater outlet hose.
  1. Install the outlet heater hose.
  2. Install the heater outlet hose (7) to the outlet hose fitting.
  3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185 .
  4. Install the heater outlet hose (3) to the heater core (1).
  5. Firmly push the quick connect onto the heater core hose until you hear an audible click.
  6. Install the transmission. Refer to «Transmission Replacement (LM4)»(ref-200406-S10258844752005102000000) or «Transmission Replacement (LL8)»(ref-200406-S32480948592005102000000) in Automatic Transmission - 4L60/4L65-E.
  7. Install the coolant bypass valve. Refer to «Coolant Bypass Valve Replacement»(ref-200405-S02566524482005102000000) .

Coolant Bypass Valve Replacement

Tools Required

  1. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(ref-200405-S14942364402005102000000) .
  2. J 38185 Hose Clamp Pliers
  1. Drain the engine coolant. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  2. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  3. Using the J 43181 , disconnect the inlet heater hose from the heater core. See «Special Tools»(ref-200405-S14942364402005102000000) . Install the J 43181 to the quick connect on the outlet heater core hose (2). See «Special Tools»(ref-200405-S14942364402005102000000) . Close the tool around the inlet heater core hose. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
  4. Position the hose clamp at the engine outlet using J 38185 .
  5. Remove the heater inlet hose (4) from the engine block.
  6. Remove the nut retaining the coolant bypass valve to the cowl.
  7. Remove the vacuum hose from the coolant bypass valve.
  8. Remove the coolant bypass valve.
  9. Position the clamps at the coolant bypass valve.
  10. Remove the heater inlet hoses form the coolant bypass valve.
  1. Apply coolant to the end of the heater inlet hoses.
  2. Install the heater inlet hose to the inlet hose fitting at the engine block.
  3. Install the coolant bypass valve (6).
  4. Install the nut retaining the coolant bypass valve to the cowl. Tighten: Tighten the nut to 10 N.m (89 lb in).
  5. Install the vacuum hose to the coolant bypass valve.
  6. Install the inlet heater hose to the engine block.
  7. Position the inlet heater hose clamp at the engine block using J 38185 .
  8. Connect the heater inlet hose to the heater core.
  9. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(ref-200409-S19424745182005102000000) in Engine Cooling.
  10. Fill the engine cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  1. Remove the cover of the under hood fuse block.
  2. Remove the blower motor relay (1) from the under hood fuse block (2).
  1. Install the blower motor relay (1) to the under hood fuse block.
  2. Install the cover of the under hood fuse block.
  1. Remove the right closeout/insulator panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-200362-S11353072362005102000000) in Interior Trim.
  2. Disconnect the blower motor resistor electrical connector (3).
  3. Remove the blower motor resistor mounting screws (2).
  4. Remove the blower motor resistor (1).
  1. Install the blower motor resistor (1).
  2. Install the blower motor resistor mounting screws (2). Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  3. Connect the blower motor resistor electrical connector (3).
  4. Install the right closeout/insulator panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-200362-S11353072362005102000000) in Interior Trim.
  1. Remove the right closeout/insulator panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-200362-S11353072362005102000000) in Interior Trim.
  2. Remove the I/P storage compartment door. Refer to «Door Replacement - Instrument Panel (I/P) Compartment»(ref-200362-S24189150632005102000000) in Instrument Panel, Gages and Console.
  3. Disconnect the blower motor electrical connector.
  4. Remove the blower motor mounting screws.
  5. Remove the blower motor cooling tube.
  6. Remove the blower motor (2).
  1. Install the blower motor (2).
  2. Install the blower motor cooling tube.
  3. Install the blower motor mounting screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Connect the blower motor electrical connector.
  5. Install the right closeout/insulator panel. Refer to «Closeout/Insulator Panel Replacement - Right»(ref-200362-S11353072362005102000000) in Interior Trim.
  1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(ref-200362-S11416393872005102000000) in Instrument Panel, Gages and Console.
  2. Remove the driver side air distributor duct screws.
  3. Remove the air distributor duct (1) from the I/P.
  4. Unclip the radio antenna wire from the duct
  5. Remove the air temperature sensor from the duct.
  1. Install the air distributor duct (1) to I/P.
  2. Install the retaining screws to the air distributor duct. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  3. Install the air temperature sensor to the air distributor duct.
  4. Clip the radio antenna wire to the duct.
  5. Install the I/P assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(ref-200362-S11416393872005102000000) in Instrument Panel, Gages and Console.
  1. Using a flat-bladed tool, release the left housing retaining pin and gently push the left side of the air outlet into the housing assembly.
  2. With the air outlet in the housing assembly, rotate the air outlet face down.
  3. Using a flat bladed tool, remove the left side of the air outlet from the housing assembly.
  4. Remove the air outlet from the housing assembly.
  1. Position the air outlet face down at the housing opening.
  2. Position the right side of the air outlet below the housing retaining pin.
  3. Seat the right side of the air outlet to the housing retaining pin by lifting upward.
  4. Seat the left side of the air outlet to the housing retaining pin.
  5. Rotate the air outlet upward past the detent position.
  6. Adjust the air outlet to the original position.
  1. Remove the left closeout/insulator panel. Refer to «Closeout/Insulator Panel Replacement - Left»(ref-200362-S01634637402005102000000) in Instrument Panel, Gages, and Console.
  2. Remove the knee bolster trim panel. Refer to «Trim Panel Replacement - Knee Bolster»(ref-200362-S15286881902005102000000) in Instrument Panel, Gages, and Console.
  3. Remove the instrument panel (I/P) cluster bezel, Chevrolet only. Refer to «Bezel Replacement - Instrument Panel (I/P) Cluster (Chevrolet)»(ref-200362-S36923661392005102000000) or «Bezel Replacement - Instrument Panel (I/P) Cluster (GMC, Buick)»(ref-200362-S16123025782005102000000) in Instrument Panel, Gages, and Console.
  4. Remove the radio. Refer to «Radio Replacement»(ref-200368-S08952960352005102000000) in Entertainment.
  5. Remove the 2 screws (1) from the bottom of the air outlet assembly.
  6. Remove the air deflectors from the outlet. Refer to «Air Outlet Replacement - Instrument Panel»(ref-200405-S35387668492005102000000) .
  7. Grasp and pull the outlet rearward from the I/P.
  8. Remove the outlet from the vehicle.
  1. If reinstalling the original outlet, install the air deflectors in the outlet. Refer to «Air Outlet Replacement - Instrument Panel»(ref-200405-S35387668492005102000000) .
  2. Install the outlet assembly to the I/P.
  3. Install the 2 retaining screws (1). Tighten: Tighten the screws to 2.5 N.m (22 lb in).
  4. Install the radio. Refer to «Radio Replacement»(ref-200368-S08952960352005102000000) in Entertainment.
  5. Install the I/P cluster bezel, Chevrolet only. Refer to «Bezel Replacement - Instrument Panel (I/P) Cluster (Chevrolet)»(ref-200362-S36923661392005102000000) or «Bezel Replacement - Instrument Panel (I/P) Cluster (GMC, Buick)»(ref-200362-S16123025782005102000000) in Instrument Panel, Gages, and Console.
  6. Install the knee bolster trim panel. Refer to «Trim Panel Replacement - Knee Bolster»(ref-200362-S15286881902005102000000) Instrument Panel, Gages, and Console.
  7. Install the left closeout/insulator panel. Refer to «Closeout/Insulator Panel Replacement - Left»(ref-200362-S01634637402005102000000) Instrument Panel, Gages, and Console.
  1. Remove the right instrument panel (I/P) access cover.
  2. Remove the screw (1) retaining the air outlet assembly to the I/P.
  3. Grasp and pull the outlet assembly rearward from the I/P.
  4. Remove the outlet assembly from the vehicle.
  1. Install the outlet assembly to the I/P.
  2. Install the retaining screw. Tighten: Tighten the screw to 2.5 N.m (22 lb in).
  3. Install the I/P access cover.
  1. Remove the console support bracket. Refer to «Bracket Replacement - Console Floor»(ref-200362-S09619410492005102000000) in Instrument Panel, Gages and Console.
  2. Drill the pop rivet (1).
  3. Rotate the air outlet duct (3) to remove the duct from the console support bracket (1).
  4. Remove the air outlet duct from the vehicle.
  1. Install the air outlet duct (3) to the console support bracket (1).
  2. Install a new pop rivet (1).
  3. Install the console support bracket. Refer to «Bracket Replacement - Console Floor»(ref-200362-S09619410492005102000000) in Instrument Panel, Gages and Console.
  1. Remove the instrument panel (I/P) trim pad. Refer to «Trim Pad Replacement - Instrument Panel (I/P) Upper»(ref-200362-S37371374902005102000000) in Instrument Panel, Gages and Console.
  2. Remove the retaining screw (4) from the side window defroster duct (3).
  3. Remove the passenger side window defroster duct.
  4. Remove the air distribution duct.
  5. Release locking tabs (2) from the defroster duct (1).
  6. Remove the defroster duct (1).
  1. Install the defroster duct.
  2. Insert defroster duct into retaining slots.
  3. Install the retaining screw (4) to the passenger side window defroster duct (3). Tighten: Tighten the nut to 2 N.m (18 lb in).
  4. Install the I/P assembly. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-200362-S10043836912005102000000) in Instrument Panel, Gages and Console.
  1. Remove the LH lower closeout/insulator panel. Refer to «Closeout/Insulator Panel Replacement - Left»(ref-200362-S01634637402005102000000) in Instrument Panel, Gages and Console.
  2. Remove the push pin (2) retaining the floor air outlet duct (1) to the heater module.
  3. Remove the floor duct (1).
  1. Install the floor air outlet duct (1) into position.
  2. Install the floor air outlet duct retaining push pin (2). Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  3. Install the LH lower closeout/insulator panel. Refer to «Closeout/Insulator Panel Replacement - Left»(ref-200362-S01634637402005102000000) in Instrument Panel, Gages and Console.
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  2. Remove the floor air outlet duct retaining screws (2,3,4).
  3. Remove the RH side floor air outlet duct (1).
  1. Install the floor air outlet duct (1) into position.
  2. Install the floor air outlet duct retaining screws (2,3,4). Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  3. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  1. Remove the HVAC module assembly (1). Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  2. Remove screws in order to separate the HVAC module assembly.
  3. Remove the screws from the air temperature actuator.
  4. Remove the air temperature actuator.
  5. Remove the screws from the mode actuator.
  6. Remove the mode actuator.
  7. Separate the HVAC module case halves.
  8. Remove the air temperature door (1) from the lower module half.
  1. Install the air temperature door (1) to the lower module half.
  2. Assemble the HVAC module case halves.
  3. Install the mode actuator.
  4. Install the screws to the mode actuator. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  5. Install the air temperature actuator.
  6. Install the screws to the air temperature actuator. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  7. Install the screws in order to assemble the HVAC module. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  8. Install the HVAC module assembly (1). Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  1. Remove the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-200362-S10043836912005102000000) in Instrument Panel, Gages and Console.
  2. Remove the screws from the defroster actuator.
  3. Remove the defroster actuator.
  4. Remove screws in order to separate the defroster/mode outlet cover (2) from the HVAC module assembly (1).
  5. Remove the defroster/mode outlet cover.
  6. Remove the defroster door (1) from the HVAC module assembly.
  1. Install the defroster door (1) to the HVAC module assembly.
  2. Install the defroster/mode outlet cover.
  3. Install the defroster/mode outlet cover screws to the HVAC module assembly (1).
  4. Install the screws to assemble the defroster/mode outlet to the HVAC module assembly. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
  5. Install the defroster actuator.
  6. Install the screws to the defroster actuator. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
  7. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-200362-S10043836912005102000000) in Instrument Panel, Gages and Console.
  1. Remove the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-200362-S10043836912005102000000) in Instrument Panel, Gages and Console.
  2. Remove the screws from the mode actuator.
  3. Remove the mode actuator.
  4. Remove screws in order to separate the defroster/mode outlet cover (2) from the HVAC module assembly (1).
  5. Remove the mode door (1) from the heater module.
  1. Install the mode door (1) to the HVAC module assembly.
  2. Install the defroster/mode outlet cover.
  3. Install the defroster/mode outlet cover screws to the HVAC module assembly (1).
  4. Install the screws to assemble the defroster/mode outlet to the HVAC module assembly. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
  5. Install the mode actuator.
  6. Install the screws to the mode actuator. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
  7. Install the I/P carrier. Refer to «Instrument Panel (I/P) Carrier Replacement»(ref-200362-S10043836912005102000000) Instrument Panel, Gages and Console.
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  2. Remove the screws retaining the recirculation assembly to the HVAC module assembly.
  3. Remove the screws from the recirculation actuator.
  4. Remove recirculation actuator.
  5. Remove the recirculation door (1) from the recirculation assembly.
  1. Install the recirculation door (1) to the recirculation assembly.
  2. Install the recirculation actuator.
  3. Install the screws to the recirculation actuator. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
  4. Install the screws to assemble the recirculation assembly. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  2. Remove the heater core access cover screws.
  3. Remove the heater core access cover.
  4. Remove the heater core (2) from the HVAC module assembly (1).
  1. Install the heater core (2) to the HVAC module assembly (1).
  2. Install the heater core access cover.
  3. Install the heater core access cover screws. Tighten: Tighten the screws to 1.9 N.m (17 lb in).
  4. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .

Scheme 2

Scheme 2: Removal Procedure
Scheme 2: Removal Procedure
  1. Remove the rear HVAC module assembly. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  2. Disconnect the electrical connector from the blower motor control processor-auxiliary (3).
  3. Remove the screws from the blower motor control processor-auxiliary (3).
  4. Remove the blower motor control processor-auxiliary (3).
  5. Remove the thermal gasket from the evaporator core-auxiliary surface.
  1. Install the thermal gasket to the blower motor control processor-auxiliary.
  2. Install the blower motor control processor-auxiliary (3).
  3. Install the screws to the blower motor control processor-auxiliary (3). Tighten: Tighten the screws to 2 N.m (18 lb in).
  4. Connect the electrical connector to the blower motor control processor-auxiliary (3).
  5. Install the HVAC module-auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  1. Remove the right rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  2. Remove the retaining bolts (5) from the HVAC module-auxiliary (1).
  3. Remove the retaining nuts (4) from the HVAC module-auxiliary (1) under the vehicle.
  4. Disconnect the electrical connectors (3,4).
  5. Remove the blower motor screws.
  6. Remove the blower motor (1) from the HVAC module-auxiliary (2).
  1. Install the blower motor-auxiliary (1) to the HVAC module-auxiliary (2).
  2. Install the blower motor-auxiliary screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
  3. Connect the electrical connectors (3,4).
  4. Install the retaining bolts (5) to the HVAC module-auxiliary.
  5. Tighten the HVAC module-auxiliary retaining bolts (5). Tighten: Tighten the bolts to 10 N.m (88 lb in).
  6. Install the retaining nuts (4) to the HVAC module-auxiliary (1) under the vehicle. Tighten: Tighten the nuts to 10 N.m (88 lb in).
  7. Install the right rear quarter trim. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  1. Remove the HVAC module-auxiliary assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  2. Disconnect the electrical connectors (4) from the blower motor-auxiliary (3).
  3. Remove the air outlet duct from the blower motor-auxiliary.
  4. Remove the screws (2,5) from the blower motor-auxiliary.
  5. Remove the blower motor-auxiliary (3).
  1. Install the blower motor-auxiliary (3).
  2. Install the retaining screws (2,5) to the blower motor-auxiliary. Tighten: Tighten the screws to 10 N.m (88 lb in).
  3. Install the air outlet duct to the blower motor-auxiliary.
  4. Connect the electrical connectors (4) to the blower motor-auxiliary (3).
  5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  1. Remove the right rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  2. Remove the lower air duct fastener (4).
  3. Remove the mid-upper air distribution fastener (6).
  4. Remove the mid-upper air distribution duct (6).
  5. Remove the lower air duct (5) from the vehicle.
  1. Install the mid-upper air distribution duct (6).
  2. Install the mid-upper air distribution fastener (7).
  3. Tighten the mid-upper air distribution screw. Tighten: Tighten the screw to 1.9 N.m (17 lb in).
  4. Install the lower air duct (5) to the vehicle. Tighten: Tighten the screw to 1.9 N.m (17 lb in).
  5. Install the lower air duct screw (4).
  6. Install the right rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  1. Remove the right rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  2. Remove the headliner. Refer to «Headliner Replacement (Envoy XUV)»(ref-200370-S26489428372005102000000) or «Headliner Replacement (TrailBlazer EXT, Envoy XL)»(ref-200370-S17161678162005102000000) or «Headliner Replacement (Trailblazer, Envoy, Rainier)»(ref-200370-S15575918612005102000000) in Interior Trim.
  3. Remove the mid upper air distribution duct retaining fastener (7).
  4. Remove the mid upper air distribution duct (6) from the C-pillar.
  5. Remove the lower air distribution duct (5) from the C-pillar.
  1. Install the lower air distribution duct (5) to the C-pillar.
  2. Install the lower air distribution duct retaining screw (4).
  3. Tighten the lower air distribution duct retaining screw. Tighten: Tighten the screw to 1.9 N.m (17 lb in).
  4. Install the upper air distribution duct (6) to the C-pillar.
  5. Install the upper air distribution duct retaining screw (7). Tighten: Tighten the screw to 1.9 N.m (17 lb in).
  6. Install the headliner. Refer to «Headliner Replacement (Envoy XUV)»(ref-200370-S26489428372005102000000) or «Headliner Replacement (TrailBlazer EXT, Envoy XL)»(ref-200370-S17161678162005102000000) or «Headliner Replacement (Trailblazer, Envoy, Rainier)»(ref-200370-S15575918612005102000000) in Interior Trim.
  7. Install the right rear quarter trim. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  1. Remove the HVAC module-auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  2. Remove the screws from heater core cover-auxiliary (3) from the HVAC module-auxiliary.
  3. Remove the heater core cover-auxiliary (3).
  4. Remove the HVAC module pass thru seal-auxiliary.
  5. Remove the heater core-auxiliary (2) from the HVAC module-auxiliary.
  1. Install the heater core-auxiliary (2) to the HVAC module-auxiliary.
  2. Install the HVAC module pass thru seal-auxiliary.
  3. Install the heater core access cover-auxiliary (3) to the HVAC module-auxiliary.
  4. Install the screws to the heater core access cover-auxiliary (3). Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the HVAC module-auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  1. Remove the right rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  2. Remove the screws from the heater core cover-auxiliary (3).
  3. Remove the heater core cover-auxiliary (3).
  1. Install the heater core cover-auxiliary (3).
  2. Install the screws to the heater core cover-auxiliary. Tighten: Tighten the screws to 2 N.m (18 lb in).
  3. Install the right rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  1. Remove the evaporator core-auxiliary. Refer to «Evaporator Core Replacement - Auxiliary»(ref-200405-S29354664572005102000000) .
  2. Remove the foam insulators (3) from the evaporator core-auxiliary lines.
  3. Remove the foam insulators from the thermal expansion valve-auxiliary (4).
  4. Using a back up wrench loosen the flare nuts from the thermal expansion valve-auxiliary.
  5. Remove the auxiliary thermal expansion valve sensing bulb and retaining clip from the evaporator core-auxiliary lines.
  6. Remove the thermal expansion valve-auxiliary from the evaporator core-auxiliary.
  7. Remove and discard the O-ring seals from the evaporator core-auxiliary. Cap or tape the lines to prevent contamination of the evaporator core-auxiliary.
  1. Remove the cap or tape from the evaporator core-auxiliary lines.
  2. Install the new O-ring. Refer to «O-Ring Replacement»(ref-200405-S33892836282005102000000) .
  3. Install the thermal expansion valve-auxiliary onto the evaporator core-auxiliary lines.
  4. Using a back up wrench, install the flare nuts from the evaporator core-auxiliary lines to the thermal expansion valve-auxiliary. Tighten: Tighten the nuts to 5 N.m (44 lb in).
  5. Install the foam insulators to the evaporator core-auxiliary lines (3).
  6. Install the foam insulators to the thermal expansion valve-auxiliary (4).
  7. Install the evaporator core-auxiliary. Refer to «Evaporator Core Replacement - Auxiliary»(ref-200405-S29354664572005102000000) .
  1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-200385-S41061932852005102000000) in General Information.
  4. Remove the nuts (3) from rear A/C line block fittings.
  5. Remove the A/C line block fittings and discard the O-ring seals.
  6. Remove the nuts from the heater hoses block fittings.
  7. Remove the heater hoses block fittings from the HVAC module-auxiliary.
  8. Remove the nuts from the HVAC module studs.
  9. Lower the vehicle.
  10. Remove the right side rear quarter trim. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  11. Disconnect the electrical connectors from the HVAC module.
  12. Disconnect the rear compartment air outlet ducts (5) from the HVAC module (3).
  13. Remove the mounting bolts (5) from the HVAC module.
  14. Remove the HVAC module (1).
  15. Remove and discard the HVAC module pass through seal.
  1. Install new HVAC module pass through seal. Refer to «HVAC Module Pass Thru Seal Replacement - Auxiliary»(ref-200405-S14987535062005102000000) .
  2. Install the HVAC module (1).
  3. Install the HVAC module mounting bolts (5). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Install the air outlet ducts (5).
  5. Connect the electrical connectors.
  6. Install the right side rear quarter trim panel. Refer to «Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL)»(ref-200370-S01979267672005102000000) or «Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Rainier)»(ref-200370-S39505008052005102000000) in Interior Trim.
  7. Raise and support the vehicle.
  8. Connect the heater hoses to the heater core.
  9. Install the nuts to the HVAC module studs. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  10. Remove the cap or tape from the A/C lines.
  11. Install the new O-ring seals. Refer to «O-Ring Replacement»(ref-200405-S33892836282005102000000) .
  12. Install the nuts (3) to the evaporator core studs. Tighten: Tighten the nuts to 20 N.m (15 lb ft).
  13. Lower the vehicle.
  14. Fill the cooling system. Refer to «Draining and Filling Cooling System (LL8)»(ref-200409-S40000666192005102000000) or «Draining and Filling Cooling System (LM4)»(ref-200409-S00791831952005102000000) in Engine Cooling.
  15. Evacuate and charge the system. Refer to «Refrigerant Recovery and Recharging»(ref-200405-S26753095092005102000000) .
  16. Leak test the fittings of the components using the J 39400-A .
  1. Remove the HVAC module-auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  2. Remove the screws from the blower motor-auxiliary.
  3. Remove the blower motor-auxiliary.
  4. Disconnect the electrical connectors.
  5. Remove the evaporator core-auxiliary. Refer to «Evaporator Core Replacement - Auxiliary»(ref-200405-S29354664572005102000000) .
  6. Remove the screws from the air temperature actuator-auxiliary.
  7. Remove the air temperature actuator-auxiliary.
  8. Disconnect the electrical connector.
  9. Remove the screws from the mode actuator-auxiliary.
  10. Remove the mode actuator-auxiliary.
  11. Disconnect the electrical connector.
  12. Remove all of the screws from the HVAC module-auxiliary.
  13. Separate the HVAC module-auxiliary case halves (2,13).
  14. Remove the mode door (15) from the HVAC module-auxiliary case half (2).
  15. Remove the air temperature door (14) from the HVAC module-auxiliary case half (2).
  1. Transfer the air temperature door (14) to the HVAC module-auxiliary case half (2).
  2. Transfer the mode door (15) to the HVAC module-auxiliary case half (2).
  3. Assemble the HVAC module-auxiliary case halves (2,13).
  4. Install all of the screws to the HVAC module-auxiliary. Tighten: Tighten the screws to 2 N.m (18 lb in).
  5. Install the mode actuator-auxiliary.
  6. Install the mode actuator-auxiliary screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
  7. Install the air temperature actuator-auxiliary.
  8. Install the air temperature actuator-auxiliary screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
  9. Install the evaporator core-auxiliary. Refer to «Evaporator Core Replacement - Auxiliary»(ref-200405-S29354664572005102000000) .
  10. Install the blower motor-auxiliary.
  11. Install the blower motor-auxiliary screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
  12. Install the HVAC module-auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  1. Remove the evaporator core-auxiliary. Refer to «Evaporator Core Replacement - Auxiliary»(ref-200405-S29354664572005102000000) .
  2. Remove the HVAC module-auxiliary case sump (4) from the HVAC module.
  1. Install the HVAC module-auxiliary case sump (4) to the HVAC module.
  2. Install the evaporator core-auxiliary. Refer to «Evaporator Core Replacement - Auxiliary»(ref-200405-S29354664572005102000000) .
  1. Remove the HVAC Module-Auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  2. Remove the screws from the heater core cover-auxiliary.
  3. Remove the heater core cover-auxiliary.
  4. Remove the HVAC pass thru seal (3) from the HVAC module-auxiliary (1).
  1. Install the HVAC pass thru seal (3) to the HVAC module-auxiliary (1).
  2. Install the heater core cover-auxiliary.
  3. Install the screws to the heater core cover-auxiliary. Tighten: Tighten the screws to 1.9 N.m (18 lb in).
  4. Install the HVAC Module-Auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  2. Remove the heater core-auxiliary. Refer to «Heater Core Replacement - Auxiliary»(ref-200405-S13659862742005102000000) .
  3. Remove the inverted TORX studs from the evaporator block-auxiliary.
  4. Remove the backing plate (1) from the evaporator core.
  5. Remove the screws from the blower motor control processor-auxiliary.
  6. Remove the blower motor control processor-auxiliary.
  7. Remove the screws from the HVAC module-auxiliary case sump (2).
  8. Remove the HVAC module-auxiliary case sump (2).
  9. Remove the evaporator core (3) from the HVAC module-auxiliary (1).
  10. Carefully remove the foam insulator (2) from around the evaporator core-auxiliary (3).
  1. If replacing the evaporator core, add the proper amount of refrigerant oil to the evaporator. Refer to «Refrigerant System Capacities»(ref-200405-S33665552472005102000000) for the capacity information.
  2. Transfer the foam insulator (2) to the replacement evaporator core-auxiliary (3).
  3. Transfer the thermal expansion valve-auxiliary to the replacement evaporator core-auxiliary. Install the evaporator core-auxiliary (3) to the rear HVAC module-auxiliary (1).
  4. Install the HVAC module-auxiliary case sump (2).
  5. Install the screws to the HVAC module-auxiliary case sump. Tighten: Tighten the screws to 2 N.m (18 lb in).
  6. Install the blower motor control processor-auxiliary.
  7. Install the backing plate (1) to the evaporator core-auxiliary.
  8. Install the evaporator block-auxiliary.
  9. Install the inverted TORX studs to the evaporator block-auxiliary. Tighten: Tighten the TORX studs to 2 N.m (18 lb in).
  10. Install the heater core-auxiliary. Refer to «Heater Core Replacement - Auxiliary»(ref-200405-S13659862742005102000000) .
  11. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(ref-200405-S37687082652005102000000) .
  12. Leak test the fittings of the component using the J 39400-A .
  1. Remove the HVAC module-auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  2. Remove the TORX studs from the evaporator block-auxiliary.
  3. Remove the evaporator block-auxiliary (1) from the HVAC module-auxiliary.
  1. Install the evaporator block-auxiliary (1) to the HVAC module-auxiliary.
  2. Install the TORX studs to the evaporator block-auxiliary. Tighten: Tighten the studs to 14 N.m (124 lb in).
  3. Install the HVAC module-auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  1. Remove the HVAC module-auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .
  2. Remove the HVAC module pass through seal (3) from the HVAC module-auxiliary (1).
  3. Remove the evaporator drain hose-auxiliary (2) from the HVAC module-auxiliary (1).
  1. Install the evaporator drain hose-auxiliary (2) to the HVAC module-auxiliary (1).
  2. Install the HVAC module pass through seal (3) to the HVAC module-auxiliary (1).
  3. Install the HVAC module-auxiliary. Refer to «HVAC Module Replacement - Auxiliary»(ref-200405-S32817568892005102000000) .

More articles — Heating, Ventilation and Air Conditioning